Bhavanee Automation Solutions
PLC and SCADA system integrator, Hyderabad

Control systems for plants that cannot stop

Since 2003, Bhavanee Automation Solutions has automated LPG bottling plants, pipeline terminals, custody transfer skids, water treatment plants, substations and pharma lines, in India and four other countries, on GE iFIX and Cimplicity.

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2003Founded
5Countries
~22LPG plants posting to SAP
20 yrsas a GE iFIX house
BAS OPERATOR STATIONLive demo --:--:--
64% 71% BULLET-01BULLET-02 P-101 RUN ESD OPEN 1214 FILLING SHEDcylinders / hr Header pressure8.82 bar LPG temperature31.0 °C Dispatch flow15.2 t/h Gas detectors0 % LEL
System healthy.

Systems running at

  • Indian Oil
  • BPCL
  • HPCL
  • GAIL
  • ONGC
  • ADNOC
  • ExxonMobil
  • Dr Reddy's
  • Aurobindo
  • Piramal
  • Gland Pharma
  • Lyophilization Systems
  • SRR Projects
  • Tata Chemicals

Industries

How each kind of plant works, what we automate in it, and the projects that prove it.

Oil and gas

LPG bottling plants, pipeline terminals, custody transfer metering and fire and gas systems for India's oil marketing companies and international operators.

IOCL, BPCL, HPCL, GAIL, ONGC, ADNOC, ExxonMobil

Water and wastewater

Water treatment plants, water supply schemes, reservoirs and pump houses under one SCADA, delivered inside EPC packages for government water supply schemes.

SRR Projects

Power and substations

IEC 61850 substation automation, SCADA with live single line diagrams and telemetry to the control centre, for distribution and plant substations.

Pharmaceuticals

Reactor, HVAC, batch and freeze dryer automation with 21 CFR Part 11 SCADA, for API and formulation plants and an OEM exporting worldwide.

Dr Reddy's, Aurobindo, Piramal, Gland Pharma, Lyophilization Systems Inc.

Process industries

Remote data acquisition, energy monitoring, batch control, tank farm inventory and furnace automation for chemicals, cement, sugar, rice and rubber plants.

Tata Chemicals, ONGC, Vishnu Cements, Andhra Sugars, Parker-Markwell

GE iFIX and Cimplicity

Twenty years on GE's SCADA platforms: what iFIX gives a plant and why operators specify it.

iFIX, Cimplicity, GE PLC

Water treatment and substations

Bhavanee delivers the SCADA and automation scope of water treatment plants and electrical substations inside EPC packages. Our water reference is the Naidupet plant for SRR Projects.

Water treatment plant SCADA

Every stage from raw water intake to the distribution pumps, sequenced and dosed by the PLC and watched from one SCADA.

How we automate a WTP
PLC + SCADA sequencing, dosing control, filter backwash, alarms, trends, quality and energy reports, remote access
IntakeScreens, raw water pumpsFT, LT
AerationCascade aerator
Flash mixerCoagulant dosingpH, FT
ClariflocculatorFlocculation, settlingTurbidity
Rapid sand filtersAutomatic backwashΔP, Turbidity
ChlorinationResidual Cl₂ trimResidual Cl₂
Clear water reservoirLevel controlLT
DistributionPumps, VFDsFT, PT, kWh
Dosing that follows the waterCoagulant and chlorine trimmed against live turbidity, pH and residual Cl₂.
Automatic backwashFilters wash on head loss or timer, with air scour sequencing.
Reports the authority needsDaily volume, quality, chemical and energy per million litres.
Remote reservoirsOHSRs, sumps and boosters report in over RTUs or 4G.

Electrical substation automation

Protection, control and metering devices integrated over IEC 61850, with a live single line diagram and telemetry to the control centre.

How we automate a substation
Substation automation architectureA control centre talks over IEC 60870-5-104 to a station gateway. SCADA servers, the operator HMI and the gateway sit on an IEC 61850 station bus carrying MMS and GOOSE. The bus feeds three bay panels, incomer, transformer and feeder, each with a protection relay, bay controller and energy meter. The panels are hardwired to a single line diagram of the incomer breaker, transformer, 11 kV busbar and two feeder breakers.1Control centreoutside the substation2Station levelwhere people operatethe substation3Station busIEC 61850 Ethernet4Bay levelone panel per bay:relay, controller, meter5Process levelthe primary equipmentThe utility's control room sees only what the gateway reports.IEC 60870-5-104 telemetryDISCOM / SLDCcontrol centreSCADA servers A / Bhot standby pair, historian,trends and reportsOperator HMIlive single line diagram,alarms, sequence of eventsGateway + GPS clockIEC 104 link to the utility,GPS time sync for all devicesMMS: measurements, statusand events reported to SCADAGOOSE: fast interlockingmessages between bays33 kV incomer bayI1Protection relayBay controllerEnergy meterTransformer bayT1Protection relayBay controllerEnergy meter11 kV feeder bayF3 / F4Protection relayBay controllerEnergy meter33 kV incomingCTbreaker33 / 11 kV transformer11 kV busbarFeeder F3Feeder F4CTs, PTs, breaker status and tripcommands are hardwired to the baysPrimary circuitHardwired copper (CT, PT, trip)IEC 61850 EthernetSimplified for clarity.
Live single line diagramBreaker states, feeder loads and alarms on one screen.
Sequence of eventsEvery trip time-stamped to the millisecond across all relays.
Transformer healthOil and winding temperature, OLTC tap, Buchholz alarms.
Control centre linkIEC 60870-5-104 to the DISCOM or SLDC.

Capabilities

One engineering team writes the logic, draws the panels, builds the screens and commissions on site. No hand-offs between vendors.

LPG bottling plant automation

Complete plant control from one control room: tank farm, pumps, carousels, interlocks and OISD-214 data sharing with the pipeline.

Custody transfer and fiscal metering

Metering skids, flow computers and meter provers, where the measurement settles money and has to stand up to audit.

Fire and gas systems

Detection, deluge valve control, sequenced fire water pumps and jockey pump pressure management to OISD-144.

Pipeline terminals and redundant SCADA

Dispatch and receipt terminals on redundant PLC and SCADA, so a single failure never stops the line.

Plant data into SAP

Live tank levels posted to SAP every morning without manual entry, running at about 22 IOCL and BPCL plants.

Water treatment plant SCADA

Intake to clear water reservoir under one SCADA: dosing against live analyzers, automatic filter backwash, quality and energy reporting.

Substation automation and SCADA

IEC 61850 integration of relays and bay controllers, SCADA with a live single line diagram, telemetry to the control centre.

Pharma automation and 21 CFR Part 11

Reactor, HVAC, batch and freeze dryer automation with audit trails, electronic records and secure batch reports.

PLC and control panel engineering

PLC panels, marshalling and SCADA workstations built to our drawings, wired, tested and documented before dispatch.

AMC, support and migration

Annual maintenance for running iFIX and GE PLC systems, and migration of legacy control systems without a long shutdown.

Real screens from systems we designed and commissioned

Storage tank level and OISD-214 signal sharing screen, IOCL Kalyani

Indian Oil (IOCL), Kalyani, West Bengal

Turnkey LPG bottling plant automation

Our largest IOCL engagement: complete automation of the LPG bottling plant with every real-time signal and safety interlock in one control system.

Level, temperature, pressure, valve status and alarms integrated in GE iFIX; full plant operation from the control room; live terminal data pushed to the connected pipeline as OISD-STD-214 requires.

  • GE iFIX
  • OISD-214
  • Turnkey

Read the case study

Plant overview screen, GAIL Vizag dispatch terminal

GAIL, Visakhapatnam

Redundant PLC and SCADA, VSPL dispatch terminal

Upgrade of the dispatch terminal at the head of the Vizag to Secunderabad LPG pipeline from another PLC make to GE, in a fully redundant configuration.

Two PLCs and two SCADA nodes in master and standby. About twenty screens: harbour receipt, receipt lines for HPCL, EIPL and GAIL, mainline pumps, interlocks, fire water, gas chromatography, rack diagnostics, vibration and power distribution.

  • GE PLC redundancy
  • Custody transfer
  • Brownfield migration

Read the case study

Skid overview screen, Abu Dhabi metering skid

ADNOC / AD Ports Group, Abu Dhabi, UAE

Natural gas custody transfer metering skid

PLC, SCADA and flow computer integration for a fiscal gas metering skid, executed with Nirmal Industrial Controls.

Emerson FloBoss S600+ flow computers calculate flow to AGA, ISO, GPA and GERG; the GE PLC handles skid logic and valves; Cimplicity shows meter runs and totals. Panels built in Mumbai to our specification.

  • GE Cimplicity
  • Emerson S600+
  • International

Read the case study

Digital fire clock, BPCL Mangalore

BPCL, Mangalore

Plant automation, fire and gas, digital fire clock

Complete LPG plant automation plus the full fire and gas system, executed in about five months.

Deluge valves, break glass units, sequenced fire engines, jockey pump and ROV control. A digital fire clock at the gate lights the zone where fire is detected, mapped across admin, MCC, sheds, pump house, gantry, sphere and bullet areas.

  • Fire and gas
  • ROV control
  • Zone annunciation

Read the case study

All projects

Before you send an enquiry

Questions buyers ask us most often.

What does Bhavanee Automation Solutions do?

We design, program and commission PLC and SCADA control systems for process plants: LPG bottling plants, pipeline dispatch and receipt terminals, custody transfer metering skids, fire and gas systems, water treatment plants, electrical substations and pharmaceutical manufacturing.

Which PLC and SCADA platforms do you work on?

Our core platform is GE: iFIX and Cimplicity SCADA with GE PLCs, including redundant controller configurations. We also integrate Honeywell HC900, ABB PLCs, Emerson S600+ flow computers and ROC controllers, numerical relays and IEC 61850 devices, analyzers and field instruments from all major makes.

Do you take complete turnkey responsibility?

Yes. A typical scope runs from I/O list and control philosophy through panel engineering, PLC and SCADA software, factory acceptance testing, installation, loop checks, commissioning, operator training and an annual maintenance contract.

Where do you execute projects?

We are based in Hyderabad and work across India. Outside India we have delivered systems in the UAE, Nigeria, Tanzania and the United States.

Do you work with EPC contractors on government tenders?

Yes. We supply the automation and SCADA scope inside EPC packages for water supply, water treatment and power distribution works. Our water treatment reference is the Naidupet plant for SRR Projects.

Planning a plant, terminal, WTP or substation?

Tell us what you are planning, even if the details are still rough. We reply with a technical approach and an offer.

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